HVOF thermal sprayed chrome replacement on hydraulic cylinders

For years, chrome plating has been utilized in the manufacture of hydraulic components on large earth moving machines. In light of rising environmental concerns with chrome plating, a thermal sprayed coating alternative is now being implemented by many manufacturers. Progressive Surface's HVOF systems have now been installed at several major heavy equipment manufacturers and maintenance and overhaul facilities around the world. Progressive Surface has the engineering expertise to design, build and integrate these complex systems handling these very large hydraulic components. Progressive Surface's controls and software provide a state-of-the-art level of integration and process control.
 

 
Shot peening and deburring large diesel engine crankshafts

Progressive has built several multi-axis gantry robotic machines to shot peen and deburr drilled oil holes in large industrial diesel engine crankshafts. Progressive Surface has mastered the process and tooling requirements to incorporate both of these operations in a single machine. In addition Progressive Surface's unique automated tailstock design allows for rapid change over from one part size to the next for optimization of productivity.
 

 
Automated cylinder head shot peening

Large industrial diesel engines operate at very high compression ratios which strain cylinder heads causing premature failures. Progressive Surface has developed automated equipment to mask, shot peen, clean, and unmask a wide variety of cylinder heads. These custom systems are extremely flexible and productive, setting the industry standard for process control and capability.
 

 
100HE anilox printing roll coating

Progressive's 100HE high enthalpy thermal spray torch produces the highest quality chrome oxide coatings on anilox rolls. The 100HE applied anilox roll coatings have a very high hardness (>1300 Hv) and very low porosity (1.0%), producing coatings which can be laser engraved at the highest numbers of lines per inch. The coating deposit efficiency produced by the 100HE for these expensive coatings is the highest available at more than 60%.
 

 
Copier roll robotic surface prep and plasma spray

Progressive Surface designed this high-production system to robotically load copier rolls into an automatic abrasive blast system to prepare for thermal spray coating. The robot then loaded the prepared roll into a thermal spray lathe where a plasma torch was robotically manipulated to precisely coat the roll. This system demonstrates Progressive Surface expertise in systems integration and automated material handling. Several unique process control and automatic measuring devices were also incorporated into this system.
 

 
Ultra high pressure waterjet stripping to recycle copier rolls

Progressive Surface has designed several unique ultra high pressure water jet systems to remove rubber and ceramic coatings from copier rolls, allowing them to then be recoated and recycled. This system incorporates Progressive Surface's vast water jet stripping process knowledge with its automation expertise to create these very productive systems.